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Production Systems Design
Types of Production Systems
Outline
Important Considerations
Types of Production Systems
Characteristics
Pros and cons.
To design a facility, we need to know
Flow How do things move around?
Space
Activity Relationships
How much room do we need?
Close together or far apart?
How do things move around? (Flow)
Lot sizes
Unit load sizes
MH Equipment
Layout arrangements
Building Configurations
How much room do we need? (Space)
Lot sizes
Storage systems
Production Equipment
Layout arrangements
Building Configurations
Personnel areas
Close together or far apart? (Relationships)
Material Flow
Personnel flow
Environmental
Teamwork
Process Requirements
The Type of Production System affects Flow, Space and Relationships…
Low Medium High
Low
Medium
High
Product Variety
Production Volume
Fixed Location Layout
Group Technology
Layout
Product Layout
Process Layout
Fixed Location Layout
Low, sporadic demand
Large products
Hard (or impossible) to move
Highly customized
“Have them come to me”
People and equipment come to the product
What to do?
Bring personnel and equipment to the product
Combine all workstations with the staging area for the product
Product
Product Layout
Designed for a specific product
Flow Lines
Sequential arrangement of equipment
High demand, low variety
What does a Product Layout look like?
T T M D G
Standardized product
Large, stable demand
Combine all workstations required to manufacture a product
Characteristics of Product Layout
Very fast – High throughput
Low WIP
Short lead times
Can be automated
Higher consistency
Specific for one product
Low flexibility
Process Layout (or Job Shop)
Higher variety
Moderate to low volumes
Not enough demand to dedicate equipment
SolutionG
P
G G
D D
D D
M M
M M
P
B B
T
T
T
Organize depts. according to processes
Machines with similar capabilities and functions
Batches might use different tooling and setups: High skill levels
G
Characteristics of Process Layout
Long throughput times
High WIP
Crossed Product routings
Harder MH and transportation
Higher Machine utilization
Process knowledge accumulation (in the workers)
Group technology
Similar parts (product families)
Enough to justify dedicated equipment
Might have similar routings
Groupings not according to physical appearance
Organize cells !
T M
M
DG
D B
DM
Configure a cell for each product family
Dedicate a set of machines in a designated physical area
Characteristics of cellular layouts
More than one machine per operator
Low WIP
Faster response to quality problems
Shorter Throughput time
Easier scheduling and control
1 2 3
4
5
678
In summary…
Characteristic Product Process Group Fixed Position
Throughput Time
W.I.P.
Skill Level Choice Mixed
Product Flexibility
Demand Flexibility
Machine Utilization
Worker Utilization
Unit Production Cost
High Low Medium Medium-High Medium-Low
What type of process would go better with…
Hospital?
Airport?
Mall? (points of view of the consumer and the stores)
Fast Food Restaurant?
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